Failure Analysis A & B

I finished my cat failure analysis tests today numbers 1 and 2 they were long roughly 60 questions on each with over 160 pages of material to cover and take notes on. I learned a lot about metallurgy. From cast to powder metal forging to quenching in water oil or air all very interesting stuff i had no idea about before this. I also learned about extrusion which is the process of forcing a piece of metal into a desired shape.We learned about heat treating metals.The Rockwell measuring system That CAT uses which measures the hardness in steel by measuring the depth of a dent, and Brinell which measures the diameter of the dent ( CAT uses Brinell to measure cast iron).We learned about brittleness and ductility in metals. We learned about tensile strength,fatigue strength,and yield strength. We learned about load types, tensile, compression, bending, torsion, and shear. the 4 characteristic that identify fractures textures, reflectivnes , surface fractures and color. All in all i learned a ton of new stuff from these two tests

A  87%
B  97%

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40 week 

120 month

Rigging and lifting

I learned how to rig and lift several different objects from engine blocks to concrete blocks. I used a rigging block and different pieces of rigging off the rigging tree. We used math to calculate the lbs of the objects before we lifted and actually weighed them .



40 week
80 month

hydraulic clamping force on a grade 5 bolt lubed and dry

I used a grade 5 bolt with a hrdraulic adapter to measure the clamping force of this bolt dry and lubed.


















40 week
40 month

McMaster car fastner id checklists

 I used McMaster Car  .Com

to get these fastener boxes identified. I will definitely be using this site for future parts number id and ordering.


40 week
152 month

Bolt Stretch Dry and Lubed Torqued to Failure

I took 4 bolts and torqued them both dry and lubed to failure to see the differences between the bolts. I started first with a 307A steel bolt at 2.26 in long and was torqued to failure dry at 64ftlbs with a overall stretch of 2.33in that's not that impressive of a bolt,lubed it did a little better and lasted until it got till 68.1ftlbs with not as much stretch as it had dry but still stretched to 2.28.Second on the table was a grade 5 bolt that was 2.285in to start and dry it failed at 134ftlbs and stretched to 2.35in, lubed it lasted to 87.7ftlbs and stretched to 2.32in. 3rd was a grade 8 bolt that started at 2.291in and after bieng torqued to 126ftlbs it failed and stretched to 2,33in. It didnt break off it stripped the threads out, lubed it lasted only to 115.4 ftlbs and stretched to 2.34in before it failed. 4th was the A325 steel bolt it started at 2.271in and dry it maxed out at 123ftlbs with a stretch to 2.26in, lubed it lasted to 122.22 with a failure at a max stretch measuring 2.29in.Its obvious to me that bolts lubed dont have the strength they do when dry on some occasions and they stretch a little bit more than they do when they are dry.

8 week
112 month

Keystock bending and twisting

Researched and checked different pieces of key stock and found the difference between two of them first was steel over-sized key stock part number 98830a610 its $1.56 a foot and it bent 90° at 130 ftlbs and broke after 1.5 turns at only 100ftlbs of pressure with the large electronic torque wrench.The second I did was with my group it was the Alloy steel over-sized key stock part number 99020a435 it was quite a bit more brittle and stronger obviously had more carbon in the steel it bent 90° at 165ftlbs and broke after only a half turn at 126.5ftlbs. I think that shows how the better the steel the more carbon is evident.Pricier steel is the way to go if its a important job your working on.

40 week
104 month

Cat recommended fuels

1. What is an ISO Cleanliness code?

                -ISO (International Standards Organization) is the protocol for expressing the level of contamination . The ISO code numbers correspond respectively to the number of particles grater than 4,6 and 14 microns 

2. What ISO cleanliness code does Cummins Inc recommend for their engines?

                -They recommend ISO code 4406

3. What are the specifications for the tank vent filter recommended by Cummins Inc?

                -98.7% efficiency at 10 microns

4. Briefly outline what Cummins Inc has to say about fuel additives. Be specific

                .-It Neither approves or dissaproves fuel additives any problems that occure while using additives is not covered by warranty.But they dont recommend fuel additives unless needed for specific applications.

5. Does Cummins Inc allow the use of bio-diesel?

                -Yes it does as long as its B100 Bio-diesel and its not recommended in low use applications such as standby power, recreational marine or seasonal applications.

6. Outline some indicators of microbial contamination of a fuel storage tank.

               -Filter Plugging and Corrosion

7. What is the amount of sulfur in low-sulfur diesel (LSD)?

              - Up to 500ppm Sulfer Content

8. What is the amount of sulfur in ultra-low-sulfur diesel (ULSD)?

              - Up to 15ppm Sulfer Content

9. What diesel fuels are currently available at the pump?

             - ULSD

10. What is the ASTM number for the Standard Specification for Diesel Fuel Oils? 

              -ASTMD975

40 week
64 month